Waterproof/breathable moisture transfer liner and composite for snowboards, alpine boots, hiking boots and the like

ABSTRACT

The waterproof/breathable moisture transfer liner for a snowboard boot includes an inner liner selected from technically advanced fabrics which are carefully selected. A series of layers are provided outside the inner liner including foam material layers, breathable membranes, a supportive mesh or a moldable foam, and an outer shell fabric. The applicability of the liner to alpine, cross country and hiking boots, along with appropriate variations for each application.

CROSS-REFERENCES

This is a continuation application of U.S. Ser. No. 11/633,513, filedDec. 5, 2006, which is a continuation application of U.S. Ser. No.10/987,162, filed Nov. 15, 2004, now abandoned, which is a continuationapplication of U.S. Ser. No. 09/500,535, filed Feb. 9, 2000, nowabandoned, which is a continuation application of U.S. Ser. No.08/910,116, filed Aug. 13, 1997, now U.S. Pat. No. 6,048,810; which is acontinuation-in-part application of U.S. Ser. No. 08/832,800, filed Apr.4, 1997, now abandoned; which is a continuation-in-part application ofU.S. Ser. No. 08/747,340, filed Nov. 12, 1996, now U.S. Pat. No.5,738,937. The entire disclosures of all of these applications arehereby incorporated by reference.

FIELD OF THE INVENTION

The present invention relates to liners used in a variety ofapplications. For example, the liner of the present invention may beemployed in a variety of applications including snowboard boots, alpineboots, cross-country boots, downhill boots and even apparel such asshirts. The liner is breathable and waterproof to increase comfort forthe rider.

BACKGROUND OF THE INVENTION

Various types of liners are known in the prior art. However, theseliners do not provide the advantages realized by the present invention.The present inventor has recognized the problems faced by snowboardriders developed liners to overcome such problems.

There is an ongoing need for comfort, breathability and support forsnowboard boot liners. In prior liner designs, a rigid, non-breathableouter material, such as vinyls, foams and nylons is often used. Theinner liners have been leather, synthetic leather, nylon or polyesterblends which extremely limited the ability to breathe or wick moistureaway from a rider's body. These materials have prevented the foot frombreathing adequately.

SUMMARY OF THE INVENTION

An object of the present invention is to provide lining system employinga warmer and more breathable liner that meets the needs of eachindividual snowboard rider. Accordingly, the liner of the presentinvention can be accommodated to the needs of snowboard riders ofvarious skill categories by permitting the inner liner material, whichis against the foot, to vary in fiber content and construction.

This object of the present invention is realized by providing a liningsystem having lining materials which act as a moisture transfer system.Moisture vapors are transferred through the liner from one side to theother side. The various lining materials can be attached to each otherby lamination, mechanical bonding (or stitch bonding as done by Tietex,Inc. or Xymid group of Dupont) or a combination of the two. Specificexamples are proved below in the description of the preferredembodiments of the present invention.

Other objects, features and advantages of the present invention willbecome readily apparent in view of the following detailed description ofthe preferred embodiments in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a first portion of the liner according to a firstembodiment of the present invention.

FIG. 2 illustrates a second portion of the liner according to a firstembodiment of the present invention.

FIG. 3 illustrates an example of the liner according to the firstembodiment of the present invention.

FIG. 4 illustrates the liner shown in FIG. 3 which will form a part of asnowboard boot.

FIGS. 5( a) and 5(b) illustrate a sole portion of a boot constructedaccording to a preferred embodiment of the present invention.

FIGS. 6 and 7 illustrate a tongue portion of a boot constructedaccording to a first embodiment of the present invention.

FIG. 8 illustrates a more detailed view of the liner portion used forthe tongue of FIGS. 6 and 7.

FIG. 9 illustrates a portion of the liner used in the upper cuff area.

FIG. 10 illustrates the travel of moisture through a reticulated foamthen a flexible mesh and into and through a breathable membraneaccording to the first embodiment of the present invention.

FIG. 11 illustrates the toe portion of a boot according to a preferredembodiment of the present invention.

FIG. 12 illustrates an overall drawing of a snowboard boot which willincorporate the liner of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following detailed description of the preferred embodiments of thepresent invention is undertaken in connection with the drawings. Thisdescription, while undertaken with respect to the disclosed embodiments,is intended to enable a variety of different applications and slightmodifications which form a part of the present invention as claimed.More specifically, many of the materials used in this lining system havebeen developed relatively recently, and in many cases are still beingmodified and improved. Where possible, tradenames of specific productshave been used to assist in the understanding of the invention. Thelining system according to the present invention can be easily adaptedto accommodate further developments in these materials. For example,while the preferred embodiments are illustratively presented below as aspecific sequence of layers, it should be understood that one or more ofthese layers may be omitted depending upon the specific needs of anyapplication. In other words, it is not strictly necessary to have acertain number of foam layers just as that disclosed in the currentlypreferred embodiment. This also applies for other elements that aredescribed. For the sake of conciseness, every possible combinationcontemplated by the inventor are not specifically enumerated. With thisin mind, the preferred embodiments currently envisioned are set forthbelow.

FIG. 1 illustrates a portion of the liner, or lining system, accordingto a first embodiment of the present invention. This embodiment isdirected to a liner for a snowboard boot which is generallynon-removable. The various layers of materials discussed below can beattached to one another is a number of ways, particularly by lamination,mechanical bonding (or stitch bonding such as that done by Tietex, Inc.or Xymed Group by Dupont) or a combination of lamination and mechanicalbonding. Mechanical bonding can be performed using nylon or LYCRA®thread, or the like. As shown in FIG. 1, a first foam material 20 isprovided between an inner liner 10 and a second foam material 30. Theinner liner 10 can be attached to the first foam material 20 bylamination or the like. The second foam material 30 is a germicidal andreticulated foam and has a thickness of approximately ¼ inch. The firstfoam material is also preferably germicidal and reticulated and has athickness of approximately ⅛ inch. All of the foam materials used in thepresent invention are assumed to be breathable and their thicknesses canbe varied depending upon specific needs. Alternatively, some of the foammaterials can be replaced with a germicidal, hydrofilic open-cell foam.For example, a foam called AQUAZONE (made by Foamex) may be used.Preferably, the AQUAZONE is attached to a non-woven top sheet made ofwood pulp, polyester, cotton, rayon, polypropylene, LYCRA® or acombination of these, etc.

The inner liner 10 is preferably constructed using specific fabricspossessing certain desired characteristics. A list of fabrics which canbe employed depending upon the individual needs of their application aswell as the individual needs of each rider are provided below. Thesefabrics may either be used individually or in combination and can bedouble sided with one fiber on one side and another on the other side.Variations for use in a snowboard boot are specifically recited.

The first fabric is an antimicrobial, antifungal polypropylene (alsoreferred to as polyolefin) LYCRA® blend (2%) with INNOVA fiber, or thelike. INNOVA is a continuous filament fiber (manufactured by DeercreekFabrics, Inc. or Menra Mills).

The second fabric is an antimicrobial, antifungal polypropylene having apolyester or cotton backing, or the like (such as that manufactured byCoville, Inc.). For uses such as for alpine boots, the polyester orcotton backing can be replaced with wool or silk.

The third fabric is an antimicrobial, antifungal polypropylene/cottonblend with ALPHA fiber (such as that manufactured by Intex Fabric,Inc.).

The fourth fabric is a field sensor polyester with waffle weaveconstruction (such as that manufactured by Toray and distributed by Yagi& Co., Inc.). Alternatively, a polyester material known as AQUA-DRY,manufactured by Teijin Shojin can be employed.

The fifth fabric is a hydrofilic antimicrobial DRI-LEX DRI-LEX BABY KIDor perforated material (such as that manufactured by Faytex Corp.).

The sixth fabric is a polyester looped terry (such as that manufacturedby Kronfli Spundale Mills, Inc.).

The seventh fabric is a sueded/sanded polyester microfiber material(distributed by Yagi & Co., Inc. and Teijin Shojin, Inc.).

The eighth fabric is POLAR TEC Series 2000, which is a wickable,moisture transfer fiber, containing LYCRA® and polypropylene. Thisfabric is also antimicrobial.

The ninth fabric is a moisture transfer fabric by Tietex, Inc.

The tenth fabric is a wool blend with a cotton, polyester or the likebacking.

Finally, spacer fabrics, polyester or polyester blends manufactured byMalden Mills and others can be used. These are composite fabrics havinglayers of fabrics.

All of these fabrics have good moisture transfer characteristics whichprevent damage to a rider's foot by preventing excessive moisturebuilt-up.

The moisture transfer characteristics of the inner liner 10 causesmoisture vapors to be passed from a rider's body through the inner liner10 where it then comes into contact with the first foam material 20. Themoisture vapors travel through the first foam material 20 and come intocontact with the abutting second foam material 30.

First foam material 20 may be a cellular elastomeric composite, or thelike, having a layer of ⅛″ germicidal, reticulated foam (or germicidal,hydrophilic open-cell foam such as AQUAZONE, or the like) backed with anonwoven top sheet comprised of wood pulp, rayon, cotton, polypropylene,polyester, LYCRA®, or a combination thereof. The cellular elastormericcomposite is formed in one process. Alternatively, foam material 20 canbe a foam that is separate from the nonwoven top sheet and is attachedto the nonwoven top sheet by lamination, stitched or ultrasonicallybonded. The nonwoven top sheet (when used) abuts the next layer of ¼″reticulated/hydrofilic open cell foam, or second foam material 30, Thesecond foam material 30 may also be a germicidal, hydrophilic, open-cell¼″ foam, such as AQUAZONE, or the like. The second foam material ispreferably backed with a nonwoven top sheet as mentioned above. In fact,any of the foam materials discussed herein can be backed by such anonwoven top sheet. Also, many of the foam materials are interchangeabledepending upon specific needs. Alternatively, the foam materials can beflame laminated to a non woven apertured top sheet of cotton,polypropylene or polyester, or a blend thereof, for example.

For example, the first foam layer 20 may also be substituted with agermicidal, hydrofilic open-cell, ⅛″ foam, such as AQUAZONE. The foamcan also be backed by non-woven top sheet. Also, a temperatureregulating membrane called OUTLAST, by Gateway Technologies can beinserted between inner layer 10 and the first foam material 20 orapplied to the fibers of layer 10.

Alternatively, Frisby Technologies can be embedded in the first opencell, hydrofilic foam layer 20 or placed in the second foam material 30.The hydrofilic foam is preferably AQUAZONE, but may be a Frisby productcalled COMFORTEMP.

The OUTLAST membrane can be placed on the other side foam, outside thenonwoven top sheet, if present. In fact, OUTLAST or Frisby may becombined with any foam or insulative layer and can be on either side.

A number of patents have been issued to Triangle Research & DevelopmentCorp. disclosing details related to the processes now being employed byGateway Technologies and Frisby. For example, U.S. Pat. Nos. 4,756,958and 5,366,801 are directed to fibers and fabrics with reversibleenhanced thermal properties, respectively. The disclosures of these twopatents are hereby incorporated by reference. Other patents assigned toTriangle Research & Development Corp., that are related by subjectmatter and have overlapping inventorship, include U.S. Pat. Nos.5,415,22, 5,290,904, and 5,244,356. These patents are also herebyincorporated by reference.

Another patent, U.S. Pat. No. 5,499,460, which has overlappinginventorship with the above-mentioned patents, is directed to a moldablefoam insole with reversible enhanced thermal storage properties. Thedisclosure of this patent is hereby incorporated by reference, and isillustrative of one type of moldable foam that can be used as mentionedherein.

As shown in FIG. 2, a third foam material 50, which provides support andhas similar characteristics to the second foam material 30, allows themoisture vapors to continue their movement toward the outside. Thisthird foam material 50 is formed in certain areas to take necessaryshapes such as the shape of an ankle, heel cup and foot bones and ispositioned so as to allow the moisture to pass through into subsequentelements, such as waterproof/breathable membrane 60 and the outer layer70 of the overall lining system. The third foam material 50 mayalternatively be a spacer fabric by Muller or the like. The spacerfabric or the third reticulated/open cell foam material 50 can bedesigned to provide a well defined heel lift, and heel pocket. Thisinvention develops the components necessary to increase technicalperformance with the increased support around the heel, toe and ankle.The toe box is from top to bottom, wider and more flexible than inprevious boot liners. The laminated foams under the heel support theriders lower back and allows for a comfortable stride. With this addedcomfort, the aggressive or recreational snowboard rider can achieve ahigher level of continued performance.

As shown in FIG. 3, between the supporting second foam material 30 andthe third foam material 50 is a structural mesh 40 which can be a flexguard, for example such as one manufactured by NALTEX or Conwed or thelike, that adds structural integrity to the lining system. A spacerfabric, moldable foam, or the like, may also be used in place of thisflex guard or mesh. Also, neither may be used is some circumstances. Themoldable foam, if not very breathable, can be made breathable bypuncturing. Alternatively, the moldable foam can be a reticulated orhydrofilic, open-cell structure, or the like. A non-woven top-sheet(with or without apertures) can be attached to the moldable foam. If amoldable foam is used, then the second foam material may be omitted.Also, the moldable foam can be AQUAZONE. Preferably, for snowboardapplications the moldable foam or spacer fabrics are used instead of theflexible mesh as layer 40.

As mentioned earlier, the third foam material 50 is preferably similarin construction to the second foam material, namely being eithergermicidal, reticulated and approximately ¼ inch thick or beinggermicidal, hydrofilic, open-cell (for example, AQUAZONE). This materialis preferably laminated to a non-woven top sheet (which may or may notbe apertured) comprised of wood pulp, rayon, or cotton. The top sheetabuts the waterproof/breathable membrane 60.

For snowboard boots, due to the cold weather conditions, a combinationof thermolite (or thermoloft) and foam or thermolite by itself ispreferably used for third foam material 50. Thermolite, manufactured byDupont, is a thin insulation having a hollow polyester fiber laid inrandom layers with an acrylic binder (loose felted) needle punchedthrough the cross section to attach layers and tie them down. Varioustypes of thermolite can be used, such as thermolite extreme, thermoloft,microloft, TFI 2000 G/M2 or TFI 4000 G/M2, etc. If encapsulation is usedin outer layer 70, as discussed herein, then it is important to usethermolite as layer 50. Again, the OUTLAST membrane or Frisby can beused in combination with third foam material 50, especially incombination with thermolite.

The moisture vapor continues from the second foam material 30 throughthe mesh or spacer material 40 and on through the third exterior foam orThermolite material 50. The moisture vapors are then passed throughwaterproof/breathable membrane 60. The moisture vapors are absorbed intothe waterproof/breathable membrane and passed through to an outer layerof fabric 70, as shown in FIG. 4. The waterproof/breathable membrane 60can be selected from a variety presently available on the market. Thoseunder the tradenames VAPEX 2000/PLUS/STANDARD/1300, SECO-TEC, THINTEC,LAY-TEK and Witcoflex Super Dry film by Baxenden Chemicals (a hydrofilicmembrane) are currently being considered. However, the membranescurrently considered to be the preferred ones are called TX-1540(application by Shawmut Mills). TX-1540 is intended to be an ultra-thin,skin friendly, moisture barrier that allows moisture vapors to escapewhile preventing outside water from penetrating. The OUTLAST membrane orthe Frisby Technologies can be used in combination with other membranes,with encapsulation techniques, or with structurally knitted fabrics andcan adjust to temperature changes. Of the various encapsulationtechniques, the one practiced by Nextec is particularly advantageous.

Also shown in FIG. 4 is an optional protective rim or cuff 80,preferably made of a slow recovery foam (by Foamex, for example) orneoprene covered by LYCRA®. Cuff 80 could also be made of a reticulatedfoam. A pull tab 90, preferably made of nylon, is connected to theprotective rim 80. A abrasive protective material 100 is providedadjacent to a tongue 300. Another abrasive protective material 110 isprovided around the heel portion of the boot. Abrasive protectivematerial 110 is supplied by Schoeller or Dupont, or the like.

The outer layer of fabric 70 of the lining system has 200 to 6000 denierstrength and is made waterproof by a membrane, encapsulation technologyor by using structurally knitted, water repelling fabrics. Encapsulationtechnology is being utilized by a company called Nextec, Inc. or Toray,Inc. (a Japanese Company or the like). Nextec Technology can be combinedwith the OUTLAST membrane or Frisby Technology. The OUTLAST membrane maybe coated or laminated to the outer fabric. If the outer fabric isencapsulated then the OUTLAST technology must be applied to the fiber orfabric prior to encapsulation. The Frisby temperature regulatingmolecules can be incorporated into the spaces between the encapsulatedfibers and may be inserted at the time of encapsulation. The breathablemembranes preserve the outer layer of fabric 70 and perform as awaterproof barrier for the boot liners. If the encapsulation technologyis applied to the outer layer of fabric 70, then the breathable laminatemembranes need not be used.

The outer layer 70 may be any of the following materials, eitherindividually or in combination. These materials include syntheticbreathable leathers, or the like, by Daowoo, Kevlar and Cordura fabrics,by Schoeller, Kelvar and technical fabrics by Dupont and Toray, Corduratreated by Encapsulation by Dupont, Travis and the like, 4 ply supplex,Cordura waterproofed by the breathable membrane, F.L. fabric by MaldenMills, DERMIZAX by Toray, ENTRANT GIL and WAXEY by Toray, GYMSTAR PLUSand TUFLEX-HR both by Unitika. The Corduras can be those made by othersas well. There are primarily three ways of protecting outer layer 70,encapsulation, using a membrane, structurally knitting the fabric torepell water or coating the fabrics with a waterproof film. Preferably,the outer layer 70 is a combination of one of the above-mentionedmaterials with one of the following: the OUTLAST or Frisby Technologiesand encapsulation by Nextec or the like, or the OUTLAST membrane orFrisby Technologies and the waterproof/breathable fabrics such asENTRANT GIL, DERMIZAX, TUFLEX or GYMSTAR. The OUTLAST membrane islaminated or coated to the outer fabric's fibers, or the FrisbyTechnology embedded in the outer fabric and then laminated to thewaterproof/breathable membrane, the Frisby or OUTLAST Technologies incombination with structurally knitted or woven waterproofed fabrics, orfinally the Frisby or OUTLAST Technologies in combination with ENTRANTGIL, Dermaizax, Turflex or GYMSTAR or the like. The outer fabrics inseveral performance catagories may not apply either Frisby or OUTLASTTechnologies.

Selecting the proper materials depends upon the needs of each individualsnowboard rider. The non-abrasive fabrics used in the moisture transferinner liner of the present invention greatly reduces the possibility oftrapped moisture, thereby protecting the foot from fungus growth and anydamage. The antifungal, antimicrobial polypropylene (polyolefin) fabricsquickly remove moisture away from the foot. Skin damage in minimizedbecause the polypropylene fabric has a smooth, continuous surface. Thisfabric also prevents bacterial build-up which can cause foot odor andfungus.

The polyester looped terry blend is an excellent wicking fabric and canremove moisture rapidly when treated with a wetting agent.

The antifungal, antimicrobial, DRI-LEX nylon fabrics, like thepolypropylene, is sanded and soft. The material not only removesmoisture from the foot, but also is extremely comfortable and cool tothe touch.

The polyester field sensor fabric works well with those individuals whoprefer riding free-style. This liner absorbs moisture immediately.

A polyester microfiber fabric is smooth to touch and wickable. A wettingagent may be added to assist in moisture transfer.

Finally, a wool blend backed with polyester or cotton or the like.

As a result of using this lining system, the rider continues to have acooler, drier foot. The lightweight kevlar, starlite, Cordura andDERMIZAX outer liner materials are twice as durable as the formerheavyweight nylons and synthetic leathers often used on the outer shell,but function as a softer, stronger feeling breathable outer surface andaid in the moisture transfer.

FIGS. 5( a) and 5(b) illustrate a sole portion 200 of a foot foam padcovered with cambrelle DRI-LEX nylon. Preferably, however, the foot padis designed using Sontara Technology nonwoven, by Dupont, and calledComforMaxSPORT, or the like. ComforMaxSPORT is backed by hydrophilicfoam and helps protect the foot bed from damage due to friction. Theinserted hydrophilic foam foot pad adds support and transfers moisturedownward. The bottom portion of the foam is preferably provided with anonwoven top sheet as described earlier. The heel pocket foam protectsthe back of the heel with a double layered reticulated support foam.This cushion protector allows circulation in the heel. ComforMaxSPORT oran antimicrobial cambrelle DRI-LEX nylon 210, or the like, covers amolded hydrophilic foam or a slow recovery foam 220 that supports thearch and insures additional comfort for a rider.

FIGS. 6, 7 and 8 illustrate the tongue 300 of the boot in more detail.The tongue is designed to add further comfort and support. As shown inFIG. 8, an inner liner fabric 310 of the tongue 300 is preferably one ofthe other inner liner materials mentioned above, especially thepolypropylene LYCRA® blend with INNOVA fiber, the polyester microfiber,the polyester looped terry or the fabrics by Malden Mills, Miliken orthe like. This inner liner fabric 310 is preferably laminated to astructural support foam 320, which is preferably a ¼ inch germicidal,reticulated foam. A hydrophilic perforated foam 330 (also could be areticulated foam, or PORON which is a slow recovery foam by Rogers,Inc., or the like) abuts a structural support foam 320. The hydrophilicperforated foam 330 can take the shape of the foot bones and protect theupper foot from damage. The structural support 320 can also be shaped toaccommodate the foot and protect the ankle bones. Optionally, a moldablespacer fabric by Muller, or the like, may also be used as portion 330. Amoisture transfer material 340 lies over the hydrophilic perforated foam330. This moisture transfer material 340 is preferably made from amaterial known as aero-spacer DRI-LEXDRI-LEX, which is manufactured byFaytex Corp, or an aero-spacer fabric manufactured by Apex Mills, or thelike. Optionally, a nonwoven material such as Sontara Technologymanufactured by Dupont can be used. In one embodiment, neither theaero-spacer or the nonwoven by Sontara Technology is used.

The nonwoven material, Sontara Technology, can be a spun lace moisturemanagement product called Typar, for example. It can have a sandedsurface treatment or it can look like steel wool and would wrap aroundthe edges of the tongue. It should be understood that these nonwovenmaterials can always be substituted for the aero-spacer DRI-LEX, even ifnot specifically mentioned in other parts of this disclosure. Thismaterial 340, is wrapped around the outer edge of the tongue to allowmoisture vapors traveling from the upper foot area to escape throughmoisture transfer material 340 to the outer surface of the tongue 300.Material 340 also aids in providing a softer edged tongue. Finally, anouter layer 350 is provided over a central portion of the material 340.Another hydrophilic, molded foam (not shown), or slow recovery form orhydrofilic foam, is shaped to fit between the outer layer 350 andmaterial 340.

As shown in FIG. 6, outer layer 350, which can be a breathable syntheticleather (by Daewoo Corp. for example) or a kevlar, or the like issurrounded by aero-spacer DRI-LEX 340, a substitute as mentioned aboveor a combination thereof. At the top of the tongue 300 is an abrasivereflective grip fabric 100 (such as that manufactured by Schoeller andidentified by the number 6500, or the like), also shown in FIG. 4.Stitching is identified by numeral 370. FIG. 7 illustrates a top portionof the tongue 300, and shows stitching 370 and the inner liner fabric310.

The liners are preferably provided with a pull tab 90 as illustrated inFIGS. 4, 9 and 10 on the back of a cuff 80 constructed of a slowrecovery foam (by Rogers, or the like) or neoprene covered by LYCRA®.Optionally, cuff 80 can be omitted altogether. FIG. 9 shows an opened upversion of the liner looking from the back of the boot. Located justbeneath the LYCRA® covered neoprene cuff 80 is a abrasive grip fabricmaterial 410, such as that manufactured by Schoeller, Inc. and referredto by the number 6500. Below material 410 is a reflective grip compositematerial 420. Below the reflective grip composite material 420 is ahighly abrasive fabric 110, as shown in FIG. 4. Fabric 110 is preferablea Kevlar or Starlite or a cordura, or the like. Finally, outer shellfabric 70 is the same as that shown in FIG. 4, and can be any of thefabrics listed previously in connection with outer shell fabric 70. Thenylon pull tab 90 allows the rider to easily slip into the liner.

FIG. 10 shows the other side of the liner of FIG. 9. In FIG. 10, 510 canbe a ¼ inch moldable foam which has been punctured or a moldable spacerfabric or the like. 520 represents the combination of the flexible meshand foam (in the case the moldable foam is not used as depicted), thebreathable membrane and the outer shell fabric. As in all of theFigures, the arrows depict the flow of moisture.

FIG. 11 illustrates the toe portion 400 of the boot. Preferably, the toeportion 400 is constructed with an inner liner 10, followed by a foammaterial 30, followed by a breathable membrane 60 and finally followedby the outer fabric 70. Foam material 30 can either be a single foam,two foams, a thermolite, a thermolite and foam combination, or any ofthese in combination with a non-woven top sheet (or a cellularelastomeric composite). Abrasive grip fabric 100 is also shown.

The 6500 high abrasive fabrics manufactured by Schoeller, Inc. or thelike are optionally located on the back of the cuff and the top of thetoe box and heel. The Kevlar and cordura, starlite fabrics providecomfort and durability to the liners and are extremely strong andresistant to abrasion and allow for breathability and performance.

FIG. 12 illustrates a snowboard boot incorporating the lining systemdiscussed above. The following elements of the snowboard boot are shown:numeral 610 represents a waterproof breathable synthetic leather, aKevlar fabric (made by Shoeller, or a similar material), Schoeller,Dupont & Toray or the like, Cordura or DERMIZAX by Toray; numeral 615represents materials similar to that of numeral 610; numeral 620 is alsosimilar to the materials of numeral 610, but can have different colorsfor aesthetic purposes; numeral 630 represents a Kevlar or a materialmade by Schoeller, or the like, with the heel portion being syntheticrubber or the like, manufactured by Daewoo; numeral 635 represents aninner moisture transfer material covering a molded breathable foam;numeral 640 represents a Kevlar or cordura material; numeral 645 ispreferably a Kevlar material; numeral 650 represents some decorativepiping made of synthetic leather or the like; numeral 655 represents apull tab made of nylon or synthetic leather; numeral 660 represents thebase of the boot which can be made of a synthetic polyurethane; numeral670 represents a reflective Kevlar back; and finally, numeral 675represents an optional sock that can be inserted into the boot ifdesired.

The sock 675 is made up of three layers. The first layer can be any ofthe inner liner materials discussed above. The second layer is a layerof foam or thermolite or a combination thereof. The third layer is afabric such as moisture transfer LYCRA® blend manufactured by DeercreekFabrics, Memra Mills or the like. Encapsulation technology can also beapplied to the third layer. Sock 675 can be used for additional warmthand is removable, unlike the boot liner. The three layers can beattached to one another by lamination, although mechanical bonding, orstitching, or ultrasonically bonded, can also be used.

The microfiber technology disclosed above is rapidly developing andchanging and has greatly increased the potential for improvedperformance of such products such as snowboard boots, provided that theyare properly utilized as in the present invention. These new productsare part of rapidly developing fabric technology. The present inventionemploys a combination of fabric, foam, moldable spacer materials andthermolite layers with breathable membranes, structurally woven orknitted waterproof fabrics, coated fabrics or encapsulated outer fabricsin such combinations that increase the performance of the products inwhich they are used as well as increase breathability. The breathablemembranes have also only recently developed and are believed to be lessthat ten years old.

While the discussion above has focused upon snowboard boots, similarapplications can be made with alpine or cross country boots, or in-lineskates, with slight modifications. For example, in the case of a crosscountry ski boot, the liner would preferably have a waterproofed outerfabric attached to a synthetic rubber base. Encapsulation technology andmembranes such as TX1540, WILCOFLEX DRY combined with the OUTLAST madeby Gateway Technologies can be employed. It is preferable to use OUTLASTor Frisby close to the individuals foot in alpine, alpine cross-country,and hiking boots. OUTLAST or Frisby Technologies may also be added toany of the inner lining material listed. Otherwise, the liner could bevery similar, although the use of the supportive mesh could be limitedto certain areas. Adjustments in the breathable membrane would be madeto accommodate winter conditions and cosmetic changes could be appliedto the surface areas.

The following is a brief discussion of the variations that arepreferably employed for a removable shell liner for alpine boots, alpinecross country boots and hiking boots. Similar names correspond tosimilar products discussed above and are not described in furtherdetail.

Alpine Boots

First, a liner for alpine boots is similar to in-line skate boots exceptthat Naltex and the like are not necessary although they can be used forhigh performance boots. This liner would have the following layers ofmaterials (additional drawings for these applications are omitted inorder to be concise). The liner will be described in a sequence oflayers beginning with the innermost layer. The first layer is selectedfrom a group including antimicrobial, anti-fungal, polypropylene INNOVAor ALPHA; DRI-LEX cambrelle or DRI-LEX Doe skin manufactured by FaytexCorp.; looped poly terry by Kronfli; DRI-LEX/Polyterry by Faytex,polypropylene or wool blends backed by another fiber for example cottonor wool or the like by Coville, Cordora; Polyester sueded or fleeced;Spacer fabrics by Malden Mills; COOL MAX by Dupont; Tietex moisturetransfer materials; or Malden Mills polyester and blends thereof, or thelike. A combination of these materials may also be employed dependingupon the needs of any individual rider.

Just as in the case of the snowboard boot, the various layers can becombined by lamination, mechanical bonding stitch bonding, ultrasonicbonding or a or a combination of these two. The second and third layerswould include a foam that contacts the first layer and is a germicidal,reticulated foam or a hydrofilic, open-cell foam, such as AQUAZONEFoamex or COMFORTEMP by Frisby or the like. Alternatively, these layerscan be a cellular elastomeric composite which is one of theabove-mentioned foams backed by a non-woven apertured top sheet composedof wood pulp, polyester, rayon, cotton, or polypropylene, in a singleprocess. Adjacent to the inner liner composite foam is a ¼″ reticulatedlayer of AQUAZONE.

The fourth layer is a molded hydrofilic AQUAZONE, slow recovery foam (byFoamex) or flex-guard or a polyester spacer material (by Muller) or thelike for support. In this case, AQUAZONE is laminated to a flatnon-woven top sheet composed of woodpulp, rayon, cotton, polyester,polypropylene which abuts a waterproof/breathable membrane (fifthlayer). If the flex-guard is used it is followed by another layer ofAQUAZONE with a top sheet abutting the waterproof/breathable membrane.

If the spacer material is used it may or may not be molded toaccommodate the foot. The non-woven top sheet will be eliminated. Thespacer material will be followed by either a waterproof membrane, anencapsulated or coated fabric. The spacer material may alternatively beused in a number of the boot layers.

The fifth layer is a waterproof/breathable membrane which may be any oneof the following: OUTLAST membrane by Gateway Technologies incombination with Seco-Tex, No. TX-1540 (laminated by Shawmut Mills),THINTEC, VAPEX 2000/1300 standard, LAYTEX and ENTRANT GIL by Toray orthe like. The OUTLAST membrane by Gateway Technologies is in conjunctionwith one of the suggested breathable membrane or the like. The laminatedor coated OUTLAST membrane may also be combined with some encapsulatedfibers and fabrics. The Frisby Technology may be embedded in the proceedfoam or Thermolite or Microloft by Dupont, but is not in combinationwith a breathable membrane. Frisby Technology can be used in conjunctionwith structurally knitted waterproof fabrics, or with the encapsulationtechnology by Nectex, Toray or the like. Encapsulation by Nexteccombined with the OUTLAST technologies is preferred. If encapsulation isemployed, than the fourth layer preferably includes thermolite. If anon-removable liner is employed instead of a removable liner, awaterproof-breathable thin film can be used instead of encapsulation ora waterproof/breathable membrane.

The sixth and final layer in this removable shell liner may be cordura,starlite, tudor, ¾/ply supplex, Kevlar fabrics, DERMIZAX or encapsulatedfabric or any combination of them. Also, a waterproof breathable thinfilm coated fabric could be used.

Alpine Cross Country Boots

A liner for the alpine cross country boots is similar to the snowboardboot liner except the cross country boot does not having a sock linerand the foams (or thermolite and foam) are thinner. This liner wouldinclude the following. A first layer selected from a group includingpolypropylene, LYCRA® or wool backed by cotton, wool, or a rayon blendor an anti-microbial, anti-fungal INNOVA or ALPHA; sueded polyester;polyester field sensor; looped polyester terry; DRI-LEX doeskin or babykid by Faytex Corp.; polyester DRI-LEX Terry by Faytex; polyester spacerfabric by Malden; and polypropylene backed by cotton by Coville.

The second layer is a germicidal open cell hydrofilic foam it may beCOMFORTEMP by Frisby or AQUAZONE with Frisby Technologies. This foam canbe provided with or without a nonwoven top sheet. The nonwoven top sheetcan be selected from any of the materials previously specified.

The third layer is a structural support foam or a moldable spacermaterial surrounding the ankle and heel. The foam may be a moldablehydrofilic AQUAZONE. The heel and arch may also have a slow recoveryfoam added for comfort. The thickness of the layer of foam or spacerfabric and Thermolite may vary for performance.

The fourth layer is a thin layer of Thermolite, or AQUAZONE or the likewith a non-woven top sheet made of wood, pulp, rayon, cotton, polyesteror polypropylene. The fourth layer may be optional in some performancecategories.

The fifth layer is a waterproof/breathable membrane which may be any oneof the following: Seco at Shawmut Mills, THINTEC, VAPEX 2000/1300standard, LAYTEX, or ENTRANT GIL by Toray. The OUTLAST membrane byGateway Technologies is employed for this layer. The OUTLAST membranecan be used by itself, with another membrane or with encapsulationtechnology, such as by Nextec, Toray or the like. Alternatively, insteadof the membrane, just encapsulation of the sixth layer can be performedto achieve similar results. A combination of OUTLAST or Frisby andencapsulation fibers or fabrics by Nextec or the like is preferred. Ifencapsulation is employed, then the fourth layer preferably includesthermolite.

The sixth layer is one of the following fabrics. Note that if thesefabrics are encasulated, the waterproof/breathable membrane in the fifthlayer may not be needed in combination. These fabrics include thefollowing: cordura; LYCRA® blends; starlite by Faytex Corp.; Kevlarfabric by Schoellar (14705, 6500, 13207, 13632, 65563, etc.); Dupont andToray or the like, Cordura 2000 by Dupont, DERMIZAX and ENTRANT GIL ByToray, 3 or 4 ply supplex; mojave and tudor nylon and polyester blendsby Travis; 6 ply maxus nylon blends or the like; and synthetic leathersby Daowoo, Inc. or the like. These fabrics may be used individually orin combination.

The seventh layer is a LYCRA® covered neoprene, moldable slow recoveryfoam or reticulated open cell foam ankle cuff.

The tongue for the alpine boot is similar to the tongue of in-lineskate. The tongue of the cross country boot is similar to the snowboardboot. They can be constructed of AQUAZONE molded foams with a top sheetor moldable spacer fabrics. A slow recovery foam can also be used asspecified with the snowboard boot. The inner fabric is one or more ofDRI-LEX Areo-spacer, polyester spacer by Malden, polypropylene, polarfleece INNOVA or ALPHA or DRI-LEX doeskin, polyester sueded or fleecedor the like. The outer tongue fabrics are high abrasive fabrics Kevlar,starlite or Schollars corduras, 6500, DRI-LEX Aero-Spacer (or otherAero-spacer materials) by Faytex, or the like, and breathable syntheticleathers by Daewoo, or the like.

Hiking Boots

A liner for the hiking boot would include the following. The first layeris selected from a group including: polyester field sensor; looped polyterry; DRI-LEX by Faytex by Faytex, Doeskin, baby kid, Cambrelle byFaytex; anti-fungal, anti-microbial polypropylene fabrics; INNOVA orALPHA, sueded polyester blends and COOL MAX, or the like. Anycombination of these can also be used.

The second layer is a cellular elastomeric composite or hydrofilic opencell AQUAZONE foam or COMFORTEMP by Frisby. This layer can be combinedwith the OUTLAST membrane. If a foam is used, a nonwoven top sheetselected from previously mentioned materials can be attached as abacking.

The third layer is a molded hydrofilic AQUAZONE backed by an aperturetop sheet composed of cotton, polyester, polypropylene, rayon orwoodpulp. A moldable heel and ankle spacer fabric by Muller or the likemay also be used in place of the third layer of hydrofilic foam ispreferably also used. A moldable slow recovery foam may be added aroundthe toe box and back cuff. A molded heel/ankle insert by Foss ispreferably also used.

The fourth layer is a waterproof/breathable membrane which may be anyone of the following: OUTLAST membrane by Gateway Technologies combinedwith Seco-Tex, TX1540 (distributed by Shawmut Mills), THINTEC, VAPEX2000/1300 standard, LAYTEX®, WILCOFLEX DRY or the like. The OUTLASTmembrane may also be used independently of the breathable membrane andmay also be coated to the outer fabric. Also, this membrane layer may beeliminated in some models depending upon the hiker's needs.Alternatively, instead of the membrane, encapsulation of the fifth layercan be performed to achieve similar results. If encapsulation isemployed, than the third layer is preferably AQUAZONE or a moldablespacer fabric or thermolite. The OUTLAST membrane can be used eitherwith another membrane or in combination with encapsulation, such as byNextec, or the like.

The fifth and last layer is a combination of one or more of thefollowing: corduras; supplex nylon; starlite; tudor; kevlar; polyesternylon blends; and breathable synthetic leathers. Preferably, this layeris waterproofed by using encapsulation, waterproof films or coatings orbreathable membranes, with or without the OUTLAST or Frisbytechnologies.

Furthermore, the breathable liner according to the present inventioncould also be added to clothing, such as shirts, pants, etc., byomitting elements such as the structural mesh and by adjusting thenumber of foam material layers and their thickness. For example,clothing preferably has a wickable inner liner, followed by an 1/16 to ⅛inch AQUAZONE foam which may be embedded with Frisby Technologies, anonwoven may or may not be laminated to the foam. A breathable membraneabuts the foam or nonwoven and is laminated to the outer fabric. Theouter fabric may be encapsulated, laminated to a breathable waterproofmembrane, coated with a waterproof film or structurally woven or knittedto repell water. Indeed the amount of foam used can be reduced due tocost consideration etc. Thermolite or Microsoft by Dupont may also beadded for colder conditions. Also, the breathable membrane may varydepending upon whether the liner will be used in the summer or winteretc. Presently, this liner system is investigating the use of polyesterspunbonded filter products by Tangerding Vlitesstoffe, Vitafiber or thelike to be used as an alternative to hydrofilic foam layers.

While the present invention has been described above in connection withthe preferred embodiments, one of ordinary skill in the art would beenabled by this disclosure to make various modifications to thedisclosed embodiments and still be within the scope and spirit of thepresent invention as recited in the appended claims.

1. A composite for footwear and apparel comprising: an inner moisturetransfer, breathable material; a breathable, moisture vaportransferring, cellular elastomeric composite comprised of a blend ofnatural and synthetic materials including a breathable, hydrophilicgermicidal, flexible, absorbent open-cell foam material and moisturevapor transferring and stretchable non-woven fibers or material, thecellular elastomeric composite being attached to the inner moisturetransfer material on a first side.